System and method for charging a barcode scanner

ABSTRACT

Cordless indicia readers may use a rechargeable energy storage unit (RESU) for power. The RESU may include either at least one lithium-ion battery or at least one super capacitor. Problems may arise when an RESU containing a lithium-ion battery is charged using a super-capacitor charging-scheme. The present invention embraces a system and method for charging a barcode scanner that includes determining the RESU type and then charging the RESU with a charging process that is appropriate for the RESU type.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. patent applicationSer. No. 14/990,861 for a System and Method for Charging a BarcodeScanner filed Jan. 8, 2016 (and published Jul. 14, 2016 as U.S. PatentApplication Publication No. 2016/0204636), now U.S. Pat. No. 9,997,935,which claims the benefit of U.S. Patent Application No. 62/101,242 for aPower Source Pack Detection filed Jan. 8, 2015. Each of the foregoingpatent applications, patent publication, and patent is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to chargers for charging a rechargeableenergy storage unit (RESU). More specifically, the present inventionrelates to a charger for a barcode scanner that is configured to detectthe barcode-scanner's RESU type and then choose a charging scheme (i.e.,charging process) appropriate for the particular RESU type.

BACKGROUND

Handheld and/or wireless barcode scanners (i.e., indicia readers) aretypically powered by a rechargeable energy storage unit (RESU).Traditionally the RESU has used a battery as its energy storagecomponent. Batteries are optimized to provide energy for prolongedperiods of continuous operation, which suits the needs for mostelectronic devices (e.g., laptops, cellphones, etc.). Barcode scanners,however, typically operate in a different fashion. Active periods areoften followed by periods of non-operation. As a result, other energystorage components may be considered for powering the barcode scanner. Asuper capacitor (i.e., ultra-capacitor, double layer capacitor, etc.),for example, may be suitable energy storage component for an RESU.

The super capacitor stores energy via a static charge rather than anelectrochemical reaction or other process. As a result, thecharging/operating characteristics required for super-capacitor RESUs isdifferent from battery RESUs. For example, a super-capacitor can becharged more quickly than a lithium-ion (Li-ion) battery. The supercapacitor may be charged/discharged many times and typically has alonger service life than a Li-ion battery. As a result, super capacitorsmay be used for barcode scanning applications, which may requireshort-term power bursts followed by quick charging periods.

The charging process (i.e., the currents/voltages applied over time) ofa super capacitor are different from a Li-ion battery. For example, thesuper capacitor may accept larger charge currents. The super capacitorcannot be overcharged and does not require the detection of afull-charge since the charge current stops flowing when the supercapacitor has reached its charge limit. A Li-ion battery, on the otherhand, requires careful control of charging current/voltage, and careshould be taken to stop charging when the battery has reached its chargelimit. In addition, safety mandates that the temperature of a Li-ionbattery be monitored and the charge/use of the Li-ion batterydiscontinued when the battery becomes excessively warm.

Either a Li-ion battery or a super capacitor may be used to as theenergy storage component in a barcode-scanner's RESU. It is desirablefor an RESU to fit/operate in any barcode-scanner/charger without regardto the type of energy storage component used by the RESU. Additionalmechanical keying features added to an RESU to indicate the RESU type(i.e., super-capacitor type or battery type) add additional costs andmay cause user frustration. One detectable difference between asuper-capacitor-type RESU and a battery-type RESU (e.g., Li-ion typeRESU) arises from the temperature sensor (e.g., thermistor) required fortemperature control in the battery-type RESU.

Traditionally, RESUs have an electrical connector (e.g., pin, tab,contact, etc.) specifically for monitoring temperature. Typically, thisconnector (i.e., thermistor pin) is connected to a thermistor within theRESU. Temperature may be detected by sensing the thermistor's resistance(i.e., the terminal resistance at the thermistor pin) since thethermistor's resistance varies with temperature (e.g., 10K ohms at roomtemperature). For a super-capacitor RESU, however, this pin may beshorted since temperature control is unnecessary. As a result, asuper-capacitor RESU and a Li-ion RESU may be visually identical butwill have different terminal resistances at their respective thermistorpins.

Therefore, a need exists for a charger that can detect what type of RESUis being charged based on the terminal resistance at the RESU'sthermistor pin and then adjust the charging process based on the type ofRESU detected.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method forselecting a charging process. The method includes the step of providinga barcode scanner that has a particular type of rechargeable storageunit (RESU). The method also includes the step of connecting the RESU toa charger that can charge the RESU with a charging process customizedfor the RESU's particular type. The charger includes a detectioncircuit, and the method includes the step of detecting the RESU'sparticular type using the detection circuit connected to a thermistorpin on the RESU. Finally, the method includes the step of selecting thecharger's charging process based on the RESU's particular type.

In an exemplary embodiment of the method, the RESU's particular type iseither (i) a super-capacitor type that includes one or moresupercapacitors for storing energy or (ii) a battery type that includesone or more batteries (e.g., one or more Li-ion batteries) for storingenergy. Further, in one possible embodiment, the shape/size andelectrical interface of the RESU is the same for each type.

In another exemplary embodiment of the method, the step of detecting theRESU's particular type includes measuring a terminal resistance, whichis the resistance of a thermistor.

In another exemplary embodiment of the method, the RESU's particulartype is either a super-capacitor type with a terminal resistance ofabout zero ohms or a battery type with a terminal resistance of about10,000 ohms.

In another exemplary embodiment of the method, the detection circuitincludes a P-channel MOSFET. The P-channel MOSFET's source is connectedto a power source, while the MOSFET's drain is connected to the input ofa current limiting resistor. The detection circuit also includes ananalog-to-digital converter (ADC). The input to the ADC is connected tothe output of the current-limiting resistor and the RESU's thermistorpin so that the terminal resistance may be measured as a voltage, andthe output of the ADC is connected to a processor, which is included aspart of the charger to control the charger's charging process. Here, theprocessor may be configured by software to (i) read the digital signaloutput from the ADC, (ii) select the charger's charging process based onthe digital signal, and (iii) control charging circuitry to applyvoltage/current to the RESU based on the selected charging process.

In another exemplary embodiment of the method, the charger is a chargingcradle that is configured to hold and charge the RESU.

In another exemplary embodiment of the method, the charger is a chargingcradle that is configured to hold and charge the RESU while the RESU isconnected to the barcode scanner.

In another aspect, the present invention embraces a charging system forcharging a wireless barcode scanner. The charging system includes awireless barcode scanner having an RESU. The charging system alsoincludes a charger that is configured to electrically connect to theRESU for charging. The charger includes a detection circuit to determinethe RESU's energy storage component. The charger also includes aprocessor that is configured to (i) receive a signal from the detectioncircuit, (ii) determine the RESU's energy storage component based on thesignal, and (iii) charge the RESU's energy storage component based onthe determination. The charging of the RESU's energy storage componentincludes the processor controlling charging circuitry to delivery energyto the RESU according to a charging process that corresponds to theRESU's energy storage component.

In one exemplary embodiment of the charging system, the RESU's storagecomponent is either one or more super capacitors or one or morelithium-ion batteries.

In another exemplary embodiment of the charging system, the RESU havingone or more super capacitors is visibly identical to the RESU having oneor more lithium-ion batteries.

In another exemplary embodiment of the charging system, the RESU'sstorage component corresponds to a terminal resistance at a thermistorpin on the RESU.

In another exemplary embodiment of the charging system, the terminalresistance for an energy storage component having one or morelithium-ion batteries is the resistance of a thermistor.

In another exemplary embodiment of the charging system, the terminalresistance for an energy storage component having one or more supercapacitors is the resistance of a short-circuit to ground.

In another exemplary embodiment of the charging system, the terminalresistance for an energy storage component having one or more supercapacitors and the terminal resistance for an energy storage componenthaving one or more lithium-ion batteries differ by more than 1000 ohms.

In another exemplary embodiment of the charging system, the detectioncircuit converts the terminal resistance at the thermistor pin into acorresponding voltage level signal. In one particular embodiment, thedetection circuit includes a P-channel MOSFET and an analog-to-digitalconverter (ADC). The MOSFET's source is connected to a power source,while the MOSFET's drain is connected to the input of a current-limitingresistor so that current flows through the current limiting resistorwhen the MOSFET is turned on for detection. The ADC's input is connectedto the output of the current-limiting resistor and the thermistor pin onthe RESU so that the voltage at the input ADC corresponds to theterminal resistance. The digital signal at the output of the ADCcorresponds to the voltage at the ADC's input.

In another exemplary embodiment of the charging system, the charger is acharging cradle having a housing configured to mechanically andelectrically mate with the RESU. The housing also contains the detectioncircuit, the processor, and the charging circuitry.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a depicts an exploded view of a barcode scanner and a rechargeableenergy storage unit (RESU) according to an embodiment of the presentinvention.

FIG. 1b graphically depicts a barcode scanner, a charger, and a powersupply according to an exemplary implementation of the presentinvention.

FIG. 2 schematically depicts a block diagram of an RESU according to anembodiment of the present invention.

FIG. 3 depicts a block diagram of a charging system for a barcodescanner according to an embodiment of the present invention.

FIG. 4 schematically depicts a detection circuit for a charger accordingto an embodiment of the present invention.

DETAILED DESCRIPTION

In one regard, the present invention embraces a system for charging arechargeable storage unit (RESU). The RESU is configured to store energyupon charging and to deliver power to a barcode scanner during thescanner's operation. The RESU may store energy in a battery or asupercapacitor. It is desirable for an RESU using a battery as itsenergy storage component to be indistinguishable (i.e., in itsmechanical structure and electrical interface) from an RESU using asuper capacitor as the energy storage component. The chargingrequirements (e.g., voltages/currents applied over time) of a batteryare different from those of a super capacitor, and charging a batteryusing a super-capacitor charging process (or vice versa) could result indamage. The present invention embraces a system to sense the RESU typeand then to charge the RESU using the appropriate charging process basedon the RESU type.

An exemplary barcode scanner 1 is shown in FIG. 1a . The barcode scannershown is intended for wireless, handheld use and scanning may beachieved by pulling a trigger. The barcode scanner may be configured toscan barcodes (e.g., 1D barcodes, 2D barcodes, etc.) or perform otheroperations, such as optical character recognition or validation (e.g.,currency, identification). The term “barcode scanner” as used herein isnot intended to limit the scope of present invention to a particulartype of indicium (e.g., barcode) that can be scanned or to a particularmeans for reading (e.g., scanning, imaging) the indicium. The barcodescanner may be a gun-style as shown in FIG. 1, but may be embodiedotherwise (e.g., body-worn type, mobile-computer type, vehicle-mountedtype, sled type, etc.).

Also shown in FIG. 1a is an RESU 10. The RESU 10, in this example, maybe inserted into the handle of the barcode scanner 1 as illustrated bythe dashed arrow. The RESU has electrical connectors 11 (e.g., pins,tabs, sockets, etc.) to interface with a charger. These electricalconnectors may include (but are not limited to) a positive pin, anegative pin (e.g., ground pin), and a thermistor pin.

An implementation of an exemplary charging system for charging is shownin FIG. 1B. As shown, a barcode scanner 1 having an RESU installed(e.g., in the handle) may be placed (i.e., as shown by the dotted arrow)onto a charger 20. The charger shown in FIG. 1B is a charging cradlethat holds the RESU 10 (and barcode scanner 1), while electricallyconnecting with the RESU connectors 11. The charger 20 may be connectedto a power supply. The power supply may include an infrastructure powersource (e.g., power at a wall outlet) and the necessary circuitry toconvert/condition the electricity available from the infrastructure intovoltages/currents suitable for the charger. In one possible embodiment,the power supply is contained within the charger's housing so that thecharger may connected directly to a wall outlet. In another possibleembodiment, the power supply is a battery.

The charging system envisioned by the present invention is not limitedto the configuration shown in FIG. 1B. The present invention alsoenvisions a charging system in which the RESU is inserted directly intothe charger after its removal from the barcode scanner. In anotherpossible embodiment, the charger includes multiple charging bays, eachconfigured to charge an RESU. In another possible embodiment, thecharger is mechanically shaped (i.e., keyed) to accept a particular RESUshape or accept a particular orientation of the RESU. In anotherpossible embodiment, the charger includes indicators and/or a display toshow the conditions of the charger/RESU (e.g., the sensed RESU type, thecharging process type, the charging status, etc.).

A block diagram of an exemplary RESU is shown in FIG. 2. The RESUincludes an energy storage element capable being charged and recharged.The energy storage element includes either a super capacitor or abattery (e.g., lithium ion battery). An RESU with at least one supercapacitor is a super-capacitor type RESU, while an RESU with at leastone Li-ion battery is a battery-type RESU. In some cases, the energystorage component may be embodied as a bank of super capacitors that areelectrically connected so as to operate as a unit. In other cases, theenergy storage component may be embodied as a bank of Li-ion batteriesthat are electrically connected so as to operate as a unit.

The RESU includes a scanner interface 14 to electrically connect withthe barcode scanner. The RESU also includes a charger interface 13 toelectrically connect with a charger. In some cases, the scannerinterface and the charger interface are included in a single interface.

For a battery-type RESU, temperature-monitoring 15 may be included. Thetemperature monitoring 15 may include a thermistor that has atemperature-dependent resistance. By sensing the thermistor'sresistance, the RESU's temperature may be monitored (e.g., 10000 ohms atroom temperature). For a super-capacitor type RESU, temperaturemonitoring is typically unnecessary. As a result, the temperaturemonitoring 15 may be eliminated or replaced.

In super-capacitor RESUs, replacing the thermistor with another circuitelement can facilitate the identification of different RESU types. Inone possible embodiment the thermistor may be replaced with a shortcircuit (e.g. to ground). In another possible embodiment, the thermistormay be replaced with an open circuit. In another possible embodiment,the thermistor may be replaced with a particular resistance (e.g., sothat the terminal resistance difference between the RESU types isgreater than about 1000 ohms).

A block diagram illustrating an exemplary charging system is shown inFIG. 3. The RESU 10 is electrically connected to a charger 20 that isalso electrically connected to a power supply 21. In some possibleembodiments, the RESU may also be connected mechanically and/orelectrically to a barcode scanner 1.

The charger 20 includes a detection circuit 30. When connected to theRESU's thermistor pin (i.e., connector, port, etc.), the terminalresistance may be measured. An RESU including at least one lithium-ion(Li-ion) battery also includes a thermistor connected to the thermistorpin so that the terminal resistance measured at the thermistor pincorresponds with the temperature inside the RESU housing (e.g., about10,000 ohms at room temperature). An RESU that includes no Li-ionbatteries (i.e., super-capacitor type RESU) does not require temperaturemonitoring, therefore the thermistor may be replaced with circuitelement having a different resistance (e.g., open-circuit,short-circuit, resistor, etc.). By detecting the resistance of thethermistor or the circuit element, the RESU type (i.e., super-capacitoror battery) may be determined.

An exemplary detection circuit 30 is schematically shown in FIG. 4.Here, a P-Channel MOSFET 31 may be used. The MOSFET's source lead (S) isconnected to a power source, and the MOSFET's drain (D) lead isconnected to the input of a current-limiting resistor 32. The output ofthe current-limiting resistor 32 is attached to an analog-to-digitalconverter (ADC) 34 input and to the RESU's thermistor pin. The voltagedrop across the terminal resistance (R_(T)) 33 measured at thethermistor pin, corresponds to the type of RESU. Likewise, the output ofthe ACD is a (digital) voltage-level signal corresponding to the type ofRESU. In the case of the Li-ion battery RESU, the ADC 34 output will befairly high as the thermistor is around 10000 ohms at ambienttemperature (e.g., 25 degrees Celsius). In the case of thesuper-capacitor RESU, the voltage will be near zero when the terminalresistance is a short circuit (i.e., short) to ground.

The gate terminal (G) for the P-channel (enhancement mode) MOSFET 31 maybe connected to bias circuitry to start/stop the current flow throughthe current limiting resistor 32. This switching aspect may be used toactivate/deactivate the sensing as necessary. Variations in theexemplary detection circuit 30 exist. For example, in one possibleembodiment, the ADC 34 is part of a processor.

As shown in FIG. 3, the output of the detection circuit 30 is connectedto the charger's processor 22. The processor may be of any type (e.g.,microcontroller, microprocessor, FPGA, ASIC, CPU, etc.) that can beconfigured by software to perform various functions and/or controlvarious devices, systems and/or components. For example, software mayconfigure the processor to receive the output (e.g., digital signalrepresenting the voltage input) of the detection circuit and determinethe proper charging scheme based on the signal. The processor 22 maythen be configured to perform the appropriate charging process bycontrolling charging circuitry 23 to deliver the appropriatevoltage/current to the RESU over time.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

1-20. (canceled)
 21. A method for selecting a charging process, themethod comprising: connecting a rechargeable energy storage unit (RESU)to a charger, the charger comprises a detection circuit configured tointerface with a pin on the RESU and to output a digital signalindicative of a terminal resistance (Rt) at the pin, wherein thedetection circuit comprises of a MOSFET that further comprises a gateterminal, a source terminal, and a drain terminal, wherein the sourceterminal is connected to a power source, and the drain terminal isconnected to a first end of a current-limiting resistor, wherein asecond end of the current-limiting resistor is connected to a digital toanalog (A/D) convertor and to a ground through the terminal resistanceat the pin of the RESU, and wherein the digital signal indicates avoltage drop across the terminal resistance (Rt) and the voltage dropacross the terminal resistance indicates a type of the RESU.
 22. Themethod according to claim 21, wherein the method further comprisesobtaining the terminal resistance from a thermistor pin at least whenthe RESU comprises a battery.
 23. The method according to claim 22,wherein the battery is a lithium-ion (Li-ion) battery.
 24. The methodaccording to claim 21, further comprising: selecting, by a processor, afirst charging process for charging a supercapacitor in response to thevoltage drop indicating a short circuit between the drain terminal andthe ground.
 25. The method according to claim 24, wherein the shortcircuit indicates a first terminal resistance value of the terminalresistance as approximately zero ohms.
 26. The method according to claim21, further comprising: selecting, by a processor, a second chargingprocess for charging a battery in response to the voltage dropindicating a presence of the terminal resistance between the drainterminal and the ground.
 27. The method according to claim 26, wherein asecond terminal resistance value of the terminal resistance is greaterthan a first terminal resistance value.
 28. The method according toclaim 21, wherein the method further comprises: ascertaining with aprocessor whether the digital signal, received from A/D convertor,indicates that the RESU comprises a supercapacitor or a battery.
 29. Themethod according to claim 21, wherein the charger comprises a cradleconfigured to hold and charge the RESU.
 30. The method according toclaim 21, wherein the charger comprises a cradle configured to hold andcharge the RESU while the RESU is connected to a barcode scanner.
 31. Acharging system for a barcode scanner, comprising: a rechargeable energystorage unit (RESU); and a charger comprising a detection circuitconfigured to interface with a pin on the RESU and to output a digitalsignal corresponding to a terminal resistance (Rt) at the pin, whereinthe detection circuit comprises a MOSFET comprising a gate terminal, asource terminal, and a drain terminal, wherein the source terminal isconnected to a power source and the drain terminal is connected to afirst end of a current-limiting resistor, wherein a second end of thecurrent-limiting resistor is connected to a digital to analog (A/D)convertor and to a ground through the terminal resistance at the pin ofthe RESU, and wherein the digital signal indicates a voltage drop acrossthe terminal resistance (Rt) and the voltage drop across the terminalresistance indicates a type of the RESU.
 32. The charging systemaccording to claim 31, wherein the pin provides a terminal resistance ofa circuit element in the RESU when the RESU comprises a supercapacitor.33. The charging system according to claim 31, further comprises: aprocessor configured to ascertain whether the digital signal, receivedfrom A/D convertor, indicates that the RESU comprises a supercapacitoror a battery, wherein the battery comprises one or more lithium-ionbatteries.
 34. The charging system according to claim 31, furthercomprises: a processor configured to select a first charging process forcharging a supercapacitor in response to the voltage drop indicating ashort circuit between the drain terminal and the ground.
 35. Thecharging system according to claim 34, wherein the short circuitindicates a first terminal resistance value of the terminal resistanceas approximately equal to zero ohms.
 36. The charging system accordingto claim 31, further comprises: a processor configured to select asecond charging process for charging a battery in response to thevoltage drop indicating a presence of the terminal resistance betweenthe drain terminal and the ground.
 37. The charging system according toclaim 35, wherein the first terminal resistance value at the pin whenthe RESU comprises the supercapacitor and a second terminal resistancevalue at the pin when the RESU comprises a battery differ by more than1000 ohms.
 38. The charging system according to claim 36, wherein asecond terminal resistance value of the terminal resistance is greaterthan first terminal resistance value.
 39. The charging system accordingto claim 33, wherein the charger is configured to: charge thesupercapacitor using a first charging process when the processor selectsa first charging process; or charge the battery using a second chargingprocess when the processor selects a second charging process.
 40. Thecharging system according to claim 31, wherein the charger comprises acradle having a housing configured to mechanically and electrically matewith the RESU, and wherein the housing contains the detection circuitand a processor.